1. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Objectives of Facility Layout Minimize material handling costs Minimize material handling costs Utilize space efficiently Utilize space efficiently Utilize labor efficiently Utilize labor efficiently Eliminate bottlenecks Eliminate bottlenecks Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers Reduce manufacturing cycle time or customer service time

2. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Process Layout Machines grouped by process they perform Machines grouped by process they perform Product Layout Product Layout Linear arrangement of workstations to produce a specific product Linear arrangement of workstations to produce a specific product Fixed Position Layout Fixed Position Layout Used in projects where the product cannot be moved Used in projects where the product cannot be moved Basic Types of Layouts

3. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout in Services Women’s lingerie Women’s dresses Women’s sportswear Shoes Cosmetics and jewelry Entry and display area Housewares Children’s department Men’s department Figure 5.1

4. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Manufacturing Process Layout L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department P P Figure 5.2

5. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Manufacturing Process Layout L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department P P Figure 5.2

6. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Manufacturing Process Layout L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department P P Figure 5.2

7. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. A Product Layout In Out Figure 5.3

8. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Comparison Of Product And Process Layouts 1.DescriptionSequential arrangementFunctional grouping of machines of machines of machines of machines 2.Type of ProcessContinuous, mass Intermittent, job shop production, mainly batch production, production, mainly batch production, assembly mainly fabrication assembly mainly fabrication 3.ProductStandardizedVaried, made to stock made to order made to stock made to order 4.DemandStableFluctuating 5.VolumeHighLow 6.EquipmentSpecial purposeGeneral purpose 7.WorkersLimited skillsVaried skills PRODUCT LAYOUTPROCESS LAYOUT Table 5.1

9. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Comparison Of Product And Process Layouts 8. InventoryLow in-process,High in-process, 8. InventoryLow in-process,High in-process, high finished goods low finished goods high finished goods low finished goods 9. Storage spaceSmallLarge 9. Storage spaceSmallLarge 10. MaterialFixed pathVariable path handling (conveyor) (forklift) handling (conveyor) (forklift) 11. AislesNarrowWide 12. SchedulingPart of balancingDynamic 13. Layout decisionLine balancingMachine location 14. GoalEqualize work atMinimize material each station handling cost each station handling cost 15. AdvantageEfficiencyFlexibility PRODUCT LAYOUTPROCESS LAYOUT Table 5.1

10. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Fixed-Position Layouts Typical of projects Typical of projects Equipment, workers, materials, other resources brought to the site Equipment, workers, materials, other resources brought to the site Highly skilled labor Highly skilled labor Often low fixed Often low fixed Typically high variable costs Typically high variable costs

11. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Designing Process Layouts Minimize material handling costs Minimize material handling costs Block Diagramming Block Diagramming Minimize nonadjacent loads Minimize nonadjacent loads Use when quantitative data is available Use when quantitative data is available Relationship Diagramming Relationship Diagramming Based on location preference between areas Based on location preference between areas Use when quantitative data is not available Use when quantitative data is not available

12. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Department12345 Load Summary Chart FROM/TODEPARTMENT 1—10050 2 —20050 360 —4050 4100 —60 550 — Example 5.1

13. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Department12345 Load Summary Chart FROM/TODEPARTMENT 1—10050 2 —20050 360 —4050 4100 —60 550 — Example 5.1 CompositeMovementsCompositeMovements 2  3200 loads3  550 loads 2  4150 loads2  550 loads 1  3110 loads3  440 loads 1  2100 loads1  40 loads 4  560 loads1  50 loads

14. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Department12345 Load Summary Chart FROM/TODEPARTMENT 1—10050 2 —20050 360 —4050 4100 —60 550 — Example 5.1 CompositeMovementsCompositeMovements 2  3200 loads3  550 loads 2  4150 loads2  550 loads 1  3110 loads3  440 loads 1  2100 loads1  40 loads 4  560 loads1  50 loads 1 2 3 4 5

15. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Department12345 Load Summary Chart FROM/TODEPARTMENT 1—10050 2 —20050 360 —4050 4100 —60 550 — Example 5.1 CompositeMovementsCompositeMovements 2  3200 loads3  550 loads 2  4150 loads2  550 loads 1  3110 loads3  440 loads 1  2100 loads1  40 loads 4  560 loads1  50 loads 1 2 3 4 5 100200 150 50 60 40 110 Grid 1

16. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Process Layout Department12345 Load Summary Chart FROM/TODEPARTMENT 1—10050 2 —20050 360 —4050 4100 —60 550 — Example 5.1 CompositeMovementsCompositeMovements 2  3200 loads3  550 loads 2  4150 loads2  550 loads 1  3110 loads3  440 loads 1  2100 loads1  40 loads 4  560 loads1  50 loads 1 2 3 4 5 100 200 150 50 60 40 110 Grid 2

17. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing Precedence diagram Precedence diagram Network showing order of tasks and restrictions on their performance Network showing order of tasks and restrictions on their performance Cycle time Cycle time Maximum time product spends at any one workstation Maximum time product spends at any one workstation

18. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing Precedence diagram Precedence diagram Network showing order of tasks and restrictions on their performance Network showing order of tasks and restrictions on their performance Cycle time Cycle time Maximum time product spends at any one workstation Maximum time product spends at any one workstation C d = production time available desired units of output Cycle time example C d = (8 hours x 60 minutes / hour) (120 units) C d = = 4 minutes 480 120

19. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Flow Time vs Cycle Time Cycle time = max time spent at any station Cycle time = max time spent at any station Flow time = time to complete all stations Flow time = time to complete all stations

20. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Flow Time vs Cycle Time Cycle time = max time spent at any station Cycle time = max time spent at any station Flow time = time to complete all stations Flow time = time to complete all stations 123 4 minutes Flow time = 4 + 4 + 4 = 12 minutes Cycle time = max (4, 4, 4) = 4 minutes

21. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Efficiency of Line  i i = 1 titititi nC a E =E =E =E =  i i = 1 titititi CdCdCdCd N =N =N =N = Efficiency Minimum number of workstations where t i = completion time for element i j = number of work elements n = actual number of workstations C a = actual cycle time C d = desired cycle time

22. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing Process 1. Draw and label a precedence diagram. 2. Calculate the desired cycle time required for the line. 3. Calculate the theoretical minimum number of workstations. 4. Group elements into workstations, recognizing cycle time and precedence constraints. 5. Calculate the efficiency of the line. 6. Stop if theoretical minimum number of workstations on an acceptable efficiency level reached. If not, go back to step 4.

23. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing WORK ELEMENTPRECEDENCETIME (MIN) APress out sheet of fruit—0.1 BCut into stripsA0.2 COutline fun shapesA0.4 DRoll up and packageB, C0.3 Example 5.2

24. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing WORK ELEMENTPRECEDENCETIME (MIN) APress out sheet of fruit—0.1 BCut into stripsA0.2 COutline fun shapesA0.4 DRoll up and packageB, C0.3 0.10.20.4 0.3 D B C A Example 5.2

25. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing WORK ELEMENTPRECEDENCETIME (MIN) APress out sheet of fruit—0.1 BCut into stripsA0.2 COutline fun shapesA0.4 DRoll up and packageB, C0.3 0.10.20.4 0.3 D B C A Example 5.2 C d = = = 0.4 minute 40 hours x 60 minutes / hour 6,000 units 2400 6000 N = = = 2.5 workstations 1.0 0.4 0.1 + 0.2 + 0.3 + 0.4 0.4

26. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing WORK ELEMENTPRECEDENCETIME (MIN) APress out sheet of fruit—0.1 BCut into stripsA0.2 COutline fun shapesA0.4 DRoll up and packageB, C0.3 0.10.20.4 0.3 D B C A Example 5.2 C d = = = 0.4 minute 40 hours x 60 minutes / hour 6,000 units 2400 6000 N = = = 2.5 workstations 1.0 0.4 0.1 + 0.2 + 0.3 + 0.4 0.4 3 workstations

27. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing WORK ELEMENTPRECEDENCETIME (MIN) APress out sheet of fruit—0.1 BCut into stripsA0.2 COutline fun shapesA0.4 DRoll up and packageB, C0.3 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5

28. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS

29. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C

30. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C B0.1C, D

31. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C B0.1C, D 2C0.0D

32. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C B0.1C, D 2C0.0D 3D0.1none

33. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.10.20.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C B0.1C, D 2C0.0D 3D0.1none A, B C D Work station 1 Work station 2 Work station 3 0.3 minute 0.4 minute 0.3 minute

34. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Line Balancing 0.1 0.2 0.4 0.3 D B C A Example 5.2 C d = 0.4 N = 2.5 REMAINING WORKSTATIONELEMENTTIMEELEMENTS 1A0.3B, C B0.1C, D 2C0.0D 3D0.1none A, B C D Work station 1 Work station 2 Work station 3 0.3 minute 0.4 minute 0.3 minute E = = = 0.833 = 83.3% 0.1 + 0.2 + 0.3 + 0.4 3(0.4) 1.0 1.2

35. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Manufacturing Cell Key: S= Saw L= Lathe HM= Horizontal milling machine VM= Vertical milling machine G= Grinder Paths of three workers moving within cell Material movement In Out Worker 1 Worker 2 Worker 3 Direction of part movement within cell S L HM VM G L Final inspection Finished part Figure 5.10

36. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Automated Manufacturing Cell Figure 5.11

37. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Flexible Manufacturing Systems Automated machining operations Automated machining operations Automated material handling Automated material handling Automated tool changers Automated tool changers Computer controlled system Computer controlled system Designed around size of parts processed & average processing time for parts Designed around size of parts processed & average processing time for parts Can process wide variety of items quickly Can process wide variety of items quickly

38. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Types Of Facilities Heavy manufacturing Heavy manufacturing Auto plants, steel mills, chemical plants Auto plants, steel mills, chemical plants Light industry Light industry Small components mfg, assembly Small components mfg, assembly Warehouse & distribution centers Warehouse & distribution centers Retail & service Retail & service

39. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Factors in Heavy Manufacturing Location Construction costs Construction costs Land costs Land costs Raw material and finished goods shipment modes Raw material and finished goods shipment modes Proximity to raw materials Proximity to raw materials Utilities Utilities Labor availability Labor availability

40. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Site Location Factors Customer base Customer base Construction/ leasing cost Construction/ leasing cost Land cost Land cost Site size Site size Transportation Transportation Utilities Utilities Zoning restrictions Zoning restrictions Traffic Traffic Safety/security Safety/security Competition Competition Area business climate Area business climate Income level Income level

41. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Location Incentives Tax credits Tax credits Relaxed government regulation Relaxed government regulation Job training Job training Infrastructure improvement Infrastructure improvement Money Money

42. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Location Analysis Techniques Location rating factor Location rating factor Center-of-gravity Center-of-gravity Load-distance Load-distance

43. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Location Rating Factor Identify important factors Identify important factors Weight factors (0.00 - 1.00) Weight factors (0.00 - 1.00) Subjectively score each factor (0 - 100) Subjectively score each factor (0 - 100) Sum weighted scores Sum weighted scores

44. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Location Factor Rating Labor pool and climate Proximity to suppliers Wage rates Community environment Proximity to customers Shipping modes Air service LOCATION FACTOR.30.20.15.15.10.05.05 WEIGHT 801006075658550 Site 1 65919580909265 Site 2 90757280956590 Site 3 SCORES (0 TO 100) Weighted Score Site 1 = (0.30)(80) = 24 Example S5.1

45. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Location Factor Rating Labor pool and climate Proximity to suppliers Wage rates Community environment Proximity to customers Shipping modes Air service LOCATION FACTOR.30.20.15.15.10.05.05 WEIGHT 801006075658550 Site 1 65919580909265 Site 2 90757280956590 Site 3 SCORES (0 TO 100) 24.00 20.00 9.00 11.25 6.50 4.25 2.50 77.50 Site 1 19.50 18.20 14.25 12.00 9.00 4.60 3.25 80.80 Site 2 27.00 15.00 10.80 12.00 9.50 3.25 4.50 82.05 Site 3 WEIGHTED SCORES Example S5.1 Weighted Score Site 1 = (0.30)(80) = 24

46. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Locate facility at center of geographic area Locate facility at center of geographic area Based on weight and distance traveled Based on weight and distance traveled Establish grid-map of area Establish grid-map of area Identify coordinates and weights shipped for each location Identify coordinates and weights shipped for each location Center-of-Gravity Technique

47. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Grid-Map Coordinates where, x, y =coordinates of the new facility at center of gravity x i, y i =coordinates of existing facility i W i =annual weight shipped from facility i  n WiWiWiWi i = 1  xiWixiWixiWixiWi n x =  n WiWiWiWi i = 1  yiWiyiWiyiWiyiWi n y = x1x1x1x1 x2x2x2x2 x3x3x3x3x y2y2y2y2y y1y1y1y1 y3y3y3y3 1 (x 1, y 1 ), W 1 2 (x 2, y 2 ), W 2 3 (x 3, y 3 ), W 3 Figure S5.1

48. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Center-of-Gravity Technique ABCD x200100250500 y200500600300 Wt7510513560 Example S5.2 y700 500 600 400 300 200 100 0 x 700500600400300200100 A B C D (135) (105) (75) (60) Miles Miles

49. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Center-of-Gravity Technique y700 500 600 400 300 200 100 0 x 700500600400300200100 A B C D (135) (105) (75) (60) Miles Miles ABCD x200100250500 y200500600300 Wt7510513560 Example S5.2 x = = = 238 n  WiWi i = 1  xiWixiWi n  n WiWi  yiWiyiWi n y = = = 444 (200)(75) + (500)(105) + (600)(135) + (300)(60) 75 + 105 + 135 + 60 (200)(75) + (100)(105) + (250)(135) + (500)(60) 75 + 105 + 135 + 60

50. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Center-of-Gravity Technique ABCD x200100250500 y200500600300 Wt7510513560 Example S5.2 y700 500 600 400 300 200 100 0 x 700500600400300200100 A B C D (135) (105) (75) (60) Miles Miles Center of gravity (238, 444)

51. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Load-Distance Technique Compute Load x Distance for each site Choose site with lowest Load x Distance Distance can be actual or straight-line

52. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Load-Distance Calculations  l i d i i = 1 n LD = LD = the load-distance value l i = the load expressed as a weight, number of trips or units being shipped from the proposed site and location i d i = the distance between the proposed site and location i d i = (x i - x) 2 + (y i - y) 2 (x,y) = coordinates of proposed site (x i, y i ) = coordinates of existing facility where,

53. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Load-Distance Example Potential Sites SiteXY 1360180 2420450 3250400 Suppliers ABCD X200100250500 Y200500600300 Wt7510513560 Compute distance from each site to each supplier = (200-360) 2 + (200-180) 2 d A = (x A - x 1 ) 2 + (y A - y 1 ) 2 Site 1 = 161.2 = (100-360) 2 + (500-180) 2 d B = (x B - x 1 ) 2 + (y B - y 1 ) 2 = 412.3 d C = 434.2 d D = 184.4 Example S5.3

54. To Accompany Russell and Taylor, Operations Management, 4th Edition,  2003 Prentice-Hall, Inc. All rights reserved. Load-Distance Example Site 2 d A = 333 d C = 226.7 d B = 323.9 d D = 170 Site 3 d A = 206.2 d C = 200 d B = 180.4 d D = 269.3 Compute load-distance i = 1 n  l i d i LD = Site 1 = (75)(161.2) + (105)(412.3) + (135)(434.2) + (60)(434.4) = 125,063 Site 2 = (75)(333) + (105)(323.9) + (135)(226.7) + (60)(170) = 99,789 Site 3 = (75)(206.2) + (105)(180.3) + (135)(200) + (60)(269.3) = 77,555* * Choose site 3 Example S5.3